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SpaceX’s Starhopper gains thruster pods as hop test preparations ramp up
Amid a flurry of new construction at SpaceX’s Boca Chica facilities, technicians have begun to install thruster pods on Starhopper in anticipation of the prototype’s first untethered flights.
According to CEO Elon Musk, Starhopper’s “untethered hover tests” will begin with just one Raptor engine installed, potentially allowing hops to restart within the next few weeks. SpaceX is currently testing Raptor SN03 (and possibly SN02) a few hundred miles north in McGregor, Texas, just a few hours’ drive south once the engine is deemed flight-ready. Meanwhile, Starhopper itself needs a considerable amount of new hardware before it can begin Raptor-powered flight testing.
A Falcon Raptor-powered Starship
Purely from a visible perspective, the most important component Starhopper is missing is a way to control its attitude and remain stable while under Raptor power, particularly critical for hovering. Enter the aptly-named attitude control system (ACS), essentially a pod of omnidirectional thrusters. SpaceX already happens to have its own extremely mature ACS proven over nearly two dozen successful Falcon 9 and Heavy booster landings, as well as every Falcon upper stage that has ever flown. SpaceX’s ACS is based on powerful nitrogen gas thrusters, known for their white puffs during Falcon 9 booster recovery and landing operations.
On May 6th and 7th, SpaceX began to install what looked like Falcon ACS pods on Starhopper. Curiously, of the two pairs of thrusters now installed, half appear to be taken directly off of older mothballed Falcon 9 boosters, while the other two seem to have been acquired from a Falcon 9 Block 5 rocket. The latter pods may very well have come from Falcon 9 B1050, the booster that unintentionally landed in the Atlantic Ocean last December.
Based on the asymmetric location of the first two pod groups, Starhopper’s ACS will probably use a tripod layout. Additionally, the reason for the thruster pairs – versus Falcon 9’s single pods – is likely simple: Starhopper is far heavier than a Falcon booster. To get the same level of control authority, SpaceX is thus pairing pods together to double the functional strength of Starhopper’s ACS.
This leads smoothly to the installation of two (likely soon to be three) new composite-overwrapped pressure vessels (COPVs). Starhopper already has two COPVs installed on the outside of its upper tank dome, now effectively confirmed to be helium containers needed to pressurize the vehicle’s methane and oxygen tanks. Based on the fact that Starhopper’s new ACS pods appear to have come straight from Falcon boosters, it’s safe to say that the 2 (or 3) new COPVs will supply the hopper’s thrusters with gaseous nitrogen.
The Ugly Starshipling
In general, this is just the latest chapter in the book of the oddity that is Starhopper. With helium tank pressurization and nitrogen ACS thrusters taken straight from Falcon 9, a major facet of SpaceX’s Mars architecture is entirely missing from the prototype. Known as autogenous pressurization, BFR was meant to use gasified versions of its onboard liquid oxygen and methane to pressurize its propellant tanks. In a similar vein, BFR was expected to integrated the same propellant into its ACS. Simply put, helium is simply out of the question if SpaceX wants to realize its reusable Mars transport architecture. Mars does have a minute quantity of nitrogen available in its already very thin atmosphere, but extracting hundreds or thousands of kilograms is impractical in the near-term, particularly if the first Starship have to carry all of their extraction equipment from Earth.
Although Musk has seemingly confirmed that Starship and Super Heavy will use ACS thrusters more akin to the Falcon family’s cold nitrogen gas pods, he did also confirm that autogenous pressurization would be a part of even the earliest iterations of the rocket. The move from carbon fiber to steel tanks likely made a major difference, as carbon composites have extremely limited heat resistance.
Without autogenous pressurization and propellant tanks closer to the thickness of orbit-capable Starships, Starhopper is really more of a mobile test stand for Raptor than anything else. The ungainly vehicle also offers SpaceX engineers an opportunity to test Starship/Super Heavy avionics in flight conditions, particularly with respect to controlling a real Raptor engine on the fly.
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Elon Musk has acknowledged that early discussions with Taiwan Semiconductor Manufacturing Company (TSMC) could bring the company into his ambitious Terafab semiconductor project, signaling a possible partnership with the world’s leading contract chipmaker.
Musk confirmed that early talks are underway, but as of right now, they are “just discussions.” There is no confirmation of a deal nor dismissal of the possibility of one, leaving open the prospect of one of the largest advanced-chip collaborations under discussion in the U.S.
@wholemars Just discussions, but something may come of it
— Elon Musk (@elonmusk) October 3, 2026
The report that speculated on potential discussions between Terafab and TSMC comes from Tim Culpan, who outlined a few ways the collaboration could operate. One is TSMC using the project as an “anchor customer” for future facilities in Texas, potentially contributing process expertise, operational know-how, or capacity while Terafab provides capital, long-term purchase commitments, or both.
Tesla and SpaceX jointly developed the Terafab project, with Intel already participating on the tech side. Elon Musk announced the project in March, and it intends to produce more than one terawatt of AI compute capacity annually once fully built.
Company statements place the first phase at approximately $16.8 billion in cost, with later filings pointing to a total that could reach well into the tens of billions across multiple stages.
Intel joined the effort in April 2026 and is expected to supply its 14A manufacturing process for the full-scale plant.
Musk has said existing suppliers, including Samsung and TSMC, remain important for near-term needs; Tesla already has production arrangements with Samsung for AI5 and AI6 chips, but that future demand from Optimus robots, Cybercab vehicles, and planned space-based data centers will eventually exceed what the global industry can currently deliver.
Terafab is positioned as the long-term answer to that projected shortfall, and Tesla did something similar during COVID to avoid a chip shortage. This is just a much larger-scale solution.
If the partnership were to materialize, it would add TSMC’s industry-leading strategies to a project that already combines Tesla’s and SpaceX’s capital and offtake with Intel’s process technology. For now, the only public confirmation is Musk’s brief acknowledgement that conversations are occurring.
Tesla’s early strategy for charging units operating within its Robotaxi fleet reveals that the company surely has not lost any of that scrappy DNA that took it from an unlikely success story to the most valuable carmaker in the world.
An observer at a Tesla Supercharger in Austin spotted ten total Robotaxi vehicles arrive: one Cybercab and nine Model Y units. A Tesla employee was waiting at the lot and allowed each unit to park itself; every car that arrived had nobody in it.
Tesla wins FCC approval for wireless Cybercab charging system
The Tesla employee would walk around and plug each car in, adjusting the parking if needed:
So look at what I found. This is how Tesla charges unsupervised robotaxis at a public supercharger. Here is a driverless Cybercab showing up with no one in it. There are 9 other Model Ys that showed up too. A Tesla employee is walking around and plugging each of them in. She also moves the cars if they are not positioned well enough to charge. I love this process. One person charges multiple robotaxis at once
— Abhimanyu Yadav (@WorldlyReviewer) October 3, 2026
It’s a very interesting strategy, but extremely understandable at this early point in the Robotaxi program. It’s only been out for about 15 months, and Cybercab just entered the fleet in early September.
On top of that, Tesla is still working tirelessly on its wireless charging apparatus, and a new patent was just published regarding that product last week.
However, this is just another example of how Tesla still has plenty of that scrappy DNA leftover from the “production hell” days, when CEO Elon Musk slept on the floor of the factory, employees were working crazy hours, Tesla was building Sprung Structures to build cars in, and the company was tiptoeing on the brink of bankruptcy.
@Teslarati Sheer magnitude of the entire production system is hard to appreciate. Almost every element of production is >75% automated. Only wire harnesses & general assembly, which are <10% of production costs, are primarily manual.
— Elon Musk (@elonmusk) October 12, 2020
For now, Tesla is utilizing a simple system for recharging its ride-hailing vehicles, and that is a Tesla employee doing it manually until another solution presents itself. Sure, it’s not the most high-tech thing, and it certainly is not what people might have expected at this point in time, but it works, and it’s keeping the entire suite running.
Tesla is expanding its Robotaxi service hours by pushing the time back by one hour, keeping the ride-hailing service operational until 11 p.m., one hour later than previously.
CEO Elon Musk confirmed the change and offered a specific reason the expansion has been gradual: the system still needs to reliably avoid small pets that are difficult to see after dark, as they commonly blend into the color of the road, especially when they’re grey.
The latest adjustment restores only a fraction of the operating window the service once held. When paid Robotaxi rides began in Austin on June 22, 2025, vehicles ran from 6 a.m. to midnight.
In September 2025, Tesla lengthened the day to a 2 a.m. close, producing a 20-hour window that stayed in place for most of the following year. By early August of this year, the cutoff had already been pulled back; an August 26 update formalized hours of 6 a.m. to 10 p.m. across Austin and several other markets.
The October move to 11 p.m. therefore leaves the Austin day one hour shorter than the original launch schedule and three hours shorter than the 2025 peak.
Musk addressed the constraint directly after the announcement. “The main thing we’re trying to solve is making sure that we don’t run over pets when they’re hard to see at night,” he wrote. “Literally trying to avoid grey kittens on grey tarmac in the dark.”
Robotaxi operating hours moved from 10pm to 11pm.
The main thing we’re trying to solve is making sure that we don’t run over pets when they’re hard to see at night. Literally trying to avoid grey kittens on grey tarmac in the dark.
— Elon Musk (@elonmusk) October 3, 2026
The example points to a low-contrast perception problem in which a small animal can blend into the road surface under limited lighting.
Tesla’s vehicles rely on cameras and neural-network processing rather than lidar; Musk has previously argued that advanced vision software can extract useful information even in low light by analyzing photon counts, but the pet-detection case remains the stated limiter in later hours.
The modest schedule change arrives alongside faster growth in the purpose-built Cybercab fleet. Texas registration data tracked by observers showed the Austin Cybercab count rising sharply in recent weeks, reaching 169 vehicles after more than 100 were added in a short span.
Tesla has indicated that a broader shift toward 24-hour operation is tied to the upcoming FSD v15 software release expected this month on Robotaxi vehicles. Until that capability is validated for the edge cases Musk described, the company continues to add service time incrementally rather than jumping straight to overnight coverage.
The one-hour extension gives Austin riders a later option for evening trips while the underlying detection work continues.
Elon Musk teases TSMC as potential Terafab partner
Tesla reveals early Robotaxi charging strategy, showing scrappy DNA
